Deformable pull plug

ABSTRACT

A reusable pull plug for masking part openings in parts to be coated or otherwise worked upon. The pull plug has particular utility in masking irregular surface portions about the part opening including, without limitation threaded, chamfered, stepped and spot faced surfaces. The pull plug is comprised of a deformable, segmented body including plug, transition and tail body segments. A flange and void volume, or “dimple,” are formed in one plug body end adjacent the plug segment. The pull plug is pulled into the part opening by the tail segment and the plug segment forms a frictional fit with the deformable body tightly sealing the part opening. The flange covers the first thread in threaded part openings and further covers chamfered, stepped and spot faced surfaces protecting those surfaces from contact by the coating or other materials. The void volume facilitates deformation of the flange and plug segment permitting the flange to conform to the surface about the part opening and permitting the pull plug to be withdrawn through the part opening in the same direction as inserted thereby avoiding damage to the applied coating material. The novel design reduces stresses on the pull plug and enables the plug to be reused through repeated coating or operation cycles.

FIELD OF THE INVENTION

[0001] This invention is related generally to masking apparatus and, more specifically, to masking apparatus for covering openings in parts during coating and other operations.

BACKGROUND OF THE INVENTION

[0002] Many types of manufactured parts, such as parts used in fabrication, aerospace and final assemblies must be coated with various materials and substances to adapt those parts for their intended end use. Such coatings are typically selected to impart desired characteristics to the coated part. For example, the coating may impart corrosion resistance to the part or may be selected to impart a selected surface finish or cosmetic appearance to the part.

[0003] As is known, many different types of materials can be applied to the parts during coating operations. These materials include, for example, nylons, polycarbonates, metals and other known materials.

[0004] There are many coating technologies available and the specific coating procedure can be selected based on the specific application. Modern coating operations include, for example, coating by powder coating, anodizing and plating. In all of these coating operations, the external surface portions of the part are completely exposed to the coating substance. For example, in powder coating operations the part to be coated is typically electrostatically charged and heated and then exposed to a fine particulate spray or fluidized bed of oppositely-charged coating particles. The particles are attracted to the surface to be coated and are melted, forming a coating over the part. In anodizing and plating operations, the part to be coated is charged and then dipped into a fluid bath containing the coating material. The coating material is attracted to the part and is deposited onto the exposed surface portions of the part.

[0005] In many applications it is necessary to mask surface portions of the part to be coated in order to prevent the coating material from coming into contact with such surface portions. The surface portions to be masked can include external surface portions as well as surface portions internal to the part. By way of further explanation, parts to be coated are three-dimensional objects which frequently consist of both external and internal surface portions. The external surface portions of these parts often include one or more part openings. During a coating operation, coating materials can migrate through these part openings and come into contact with the internal surface portions of the part. Depending on the specific application for the part, contact between the coating and the internal surface portions of the part can be undesirable and can severely damage the part.

[0006] Complicating the need to mask part openings is the fact that many part openings are threaded with the threads being provided for mating engagement with a threaded fastener or another part. These threads about the part opening pose a particular problem with respect to limiting the migration of coating material into the interior portions of the part. More specifically, the protruding threads interfere with the operator's ability to form a complete seal over the part opening blocking the flow of coating material into the part. If unsealed, the threads provide a helical passageway directing coating materials to the interior of the part.

[0007] Yet another complication involving threaded openings relates to the fact that the first thread of the threaded opening is typically chamfered and is not flat or smooth. The chamfered edge further interferes with the ability to form a complete seal over the opening. Failure to fully mask the first thread of the chamfered opening may permit coating materials to contact and build up on the threads damaging the threads and preventing engagement with the fastener or other part following completing of the coating or other work process. Unwanted application of coating to the threads can result in costly re-working expenses or loss of the part.

[0008] Parts to be coated may also include cast or machined “countersunk” portions about the part opening. Such countersunk portions could include, for example, a tapered annular portion having a frusto-conical geometry located about the annulus of a cylindrically-shaped part opening. The different surface geometries about the part opening present an obstacle to forming a complete mask over such surfaces.

[0009] The need to mask or otherwise protect the surface of a part opening is not limited to coating operations. For example, in certain manufacturing processes it may be necessary to weld components or otherwise work on the part at locations near the part opening. Care must be taken to avoid contamination of the part and part opening because debris from the welding or work process can become deposited on the part opening near the weldment. As will be readily understood by those of skill in the art, serious contamination of a threaded part opening tapped directly into the part could potentially result in loss of the entire part.

[0010] One illustrative manufacturing process which requires avoidance of work-related contamination of the part opening involves “weld nuts” which are commonly used in industry to secure parts one to the other. A weld nut is secured to the plate or part by welding with the weld nut in coaxial alignment with a hole or opening in the plate. A bolt or other threaded part may then be secured to the plate or part in threaded engagement with the weld nut. During manufacturing of the product, flux and metal contaminants from welding operations near the weld nut can undesirably become attached to the weld nut in or near the weld nut threaded opening. Any such contamination may require costly cleaning or re-working of the threaded opening in the weld nut or may even require removal of the weld nut. Avoidance of such contamination necessitates use of a masking device to protect the weld nut opening from contact by the contaminants. Further, the weld nut opening must be protected from contact with coating materials if the part including the weld nut is to be, for example, powder coated following manufacture.

[0011] Yet a further factor complicating coating and manufacturing processes is the fact that there is an almost infinite variation in the types of part openings that may be encountered. The size, shape and configuration of part openings can vary significantly from part to part. Each different type of part opening potentially represents a unique set of problems with respect to masking of the opening.

[0012] Many products have been developed to mask, or close, part openings in an ongoing effort to prevent coating materials, contaminants and other materials from coming into contact with the internal surface portions of parts and part openings. For example, various plugs are commercially available to mask openings in the part to be coated. Such plugs are available in many sizes and shapes and include configurations ranging from gently tapered annular plug bodies to plug bodies having pronounced conical designs. For instance, some plugs are provided with a tapered outer body. At least a portion of the tapered plug body has an outside diameter which is larger than the inside diameter of the opening. The tapered plug is held firmly in place by the frictional fit between the plug outer body and the walls forming the part opening.

[0013] “Pull plugs” are one specific type of known masking device used to mask part openings. Conventional pull plugs have a solid, continuous body consisting of a plug portion, a tapered transition portion and a tail portion. Such pull plugs are typically made of silicone rubber and have a durometer of about 55+/−5 on the Shore A scale. The pull plug is selected so that the plug portion will form a friction fit with the part opening. The use of higher durometer material requires that the plug be sized to a specific opening size, again limiting use of each pull plug to a narrow range of part opening sizes.

[0014] One advantage of pull plugs is that such plugs may be removed in the same direction in which they are inserted thereby avoiding damage to the applied coating. Following coating, the tail is grasped and the plug is pulled through the opening in the same direction as it was inserted.

[0015] Conventional plugs, including pull plugs, are available in many types of materials including, for example, cork, silicone and EPDM rubber. Conventional plugs are typically configured to the specific shape and size of the opening to be masked. Because thousands of masking devices may be required for a large production run, the operator is required to maintain a large inventory of plugs. As can be readily understood, any requirement to maintain an unnecessarily large inventory of plugs imposes added costs on the operator which could otherwise be avoided.

[0016] A leading supplier of plugs, pull plugs and other masking products is Engineered Products and Services, Inc. of Menominee Falls, Wis. (EPSI). EPSI is the assignee of this patent application.

[0017] While conventional plugs are very effective in masking typical part openings, such plugs are less than fully effective in masking specialized part openings such as threaded openings, countersunk openings and other openings having more unique configurations. For example, conventional plugs, including pull plugs, may form an incomplete seal with the threads surrounding the opening. A less than complete seal may be formed because the more rigid material typically used to make these plugs does not fully seal the helical passageway formed by the threads.

[0018] By way of further example, conventional plugs, including pull plugs, lack structure to shield the chamfered edge of the threaded opening from contact with coating material or contaminants. The plugs which do include such structure have separate disadvantages. For example, “washer plugs” are commonly used to mask the threads of threaded part openings from contact with the coating material. Such washer plugs are made of a rigid silicone rubber material having a durometer of about 55+/−5 on the Shore A scale and have a flange which is provided to cover the first thread. The higher durometer material used in the washer flanges limits the capability of the plug to conform to the irregular surfaces about the part opening. A further disadvantage of washer plugs involves the fact that such plugs must be removed from the part opening in a direction opposite to the direction in which the plug was inserted. Removal of the washer plug in the direction opposite to the direction of insertion can result in an irregular tearing of the applied coating material around the location of the plug damaging the coated part.

[0019] As a further example, conventional plugs, including pull plugs, are also ineffective in masking countersunk portions about the part opening, such as the tapered annular portions located about the annulus of a part opening. Such conventional plugs are not effective in masking the countersunk portion because the plug body is sized to approximate the opening and is not sized sufficiently to mask the larger countersunk region surrounding the opening.

[0020] It would be significant improvement in the art to provide an improved plug which would be useful for masking one or more openings in a part to be coated or otherwise involved in a work process, which would conform to the irregular surface portions about the part opening, which would protect such part opening surface portions from unwanted contact by coatings and other materials, which would be removable in the same direction as inserted, which would prevent passage of liquids and other materials through the part opening and into contact with internal surface portions of the part, which would be simple and easy to use and which would be reusable.

OBJECTS OF THE INVENTION

[0021] It is an object of this invention to provide an improved pull plug which overcomes problems and shortcomings of the prior art.

[0022] Another object of this invention is to provide an improved pull plug which masks a part opening, particularly to prevent coatings and other materials from contacting the part opening.

[0023] An additional object of this invention if to provide an improved pull plug which fully masks irregular surfaces about a part opening including, without limitation, chamfered, stepped, spot faced and threaded surfaces.

[0024] Yet another object is to provide an improved pull plug which is simple and easy to use.

[0025] Still another object of this invention is to provide an improved pull plug that can be removed in the same direction in which it was inserted.

[0026] A further object of this invention is to provide an improved pull plug that can mask a range of part opening sizes thereby permitting the operator to maintain a smaller inventory of masking devices.

[0027] An additional object is to provide an improved pull plug which is reusable.

[0028] How these and other objects are accomplished will be apparent from the descriptions of this invention which follow.

SUMMARY OF THE INVENTION

[0029] The invention is reusable pull plug useful for masking an opening in a part thereby preventing coating or other materials from coming into contact with the part opening or with interior portions of the part. In general, the pull plug has a body with first and second ends, a body axis and an axial length between the first and second ends. Preferably, the plug body is made of an elastomeric material having a durometer of between about 30-45 on the Shore A scale. A more preferred plug body durometer is between 35-45 on the Shore A scale. Most preferably, the pull plug body is a unitary elastomeric element.

[0030] The preferred plug body is “segmented” in that it consists of defined body portions. These body portions or segments preferably comprise cylindrically-shaped plug and tail segments and a tapered transition segment positioned between the plug and tail segments. A flange is provided in the body first end adjacent the plug segment. Preferably, the flange, plug, transition and tail segments are coaxially aligned with the body axis and are concentric to one another.

[0031] A void volume or small indentation in the form of a “dimple” is provided in the plug body first end. The void volume is provided to permit radially-inward deformation of the flange and plug body segment.

[0032] The pull plug is seated in the part opening so that the plug segment is in frictional engagement with the part opening wall or threads. The plug segment and flange deform to conform to the shape of the part opening. Such deformation is the result of the low-durometer material comprising the plug body and the radially-inward movement of the flange and plug segment permitted by the void volume. The flange covers the edge of the part opening preventing coating or other materials from coming into contact with the first thread or with the part opening. The plug segment masks the part opening and prevents coatings or other material from moving through the opening.

[0033] The pull plug disclosed herein masks a broad range of part openings. The plug structure permits the plug to deform to cover irregular surfaces. Such irregular surfaces can include chamfered, stepped, spot faced and threaded surfaces which are difficult to mask with conventional plugs. The pull plug is removable in the same direction as inserted into the part opening thereby minimizing any potential damage to the coating applied to the part. The pull plug is simple to use and is reusable over many operational cycles.

DESCRIPTION OF THE DRAWINGS

[0034]FIG. 1 is a perspective view of an exemplary pull plug according to the invention taken from a position slightly above the plug.

[0035]FIG. 2 is a perspective view of an exemplary pull plug according to the invention taken from a position slightly below the plug.

[0036]FIG. 3 is a top view of an exemplary pull plug according to the invention.

[0037]FIG. 4 is a bottom view of an exemplary pull plug according to the invention.

[0038]FIG. 5 is a side elevation of an exemplary pull plug according to the invention.

[0039]FIG. 6 is a cross-sectional view of an exemplary pull plug according to the invention take along section line 6-6 of FIG. 5.

[0040]FIG. 6A is an enlarged partial cross-sectional view of the first end and plug segment of an exemplary pull plug according to the invention taken along section 6A-6A of FIG. 6.

[0041]FIG. 7 is a side elevation view of an exemplary pull plug according to the invention shown partially inserted into a weld nut secured to a plate.

[0042]FIG. 7A is a cross-sectional view of the partially-inserted exemplary pull plug of FIG. 7 taken along section line 7A-7A of FIG. 7.

[0043]FIG. 8 is a top view of the partially-inserted exemplary pull plug of FIG. 7.

[0044]FIG. 9 is a perspective view of the partially-inserted exemplary pull plug of FIG. 7 taken from a position slightly above the plug.

[0045]FIG. 10 is a side elevation view of the exemplary pull plug of FIGS. 7-9 shown fully inserted into the weld nut secured to the plate.

[0046]FIG. 10A is an enlarged partial side elevation view of the fully-inserted exemplary plug of FIG. 10 taken along section 10A-10A of FIG. 10.

[0047]FIG. 11 is a perspective view of the fully-inserted exemplary pull plug of FIG. 10 taken from a position slightly above the plug.

[0048]FIG. 12 is a cross-sectional view of the exemplary pull plug of FIG. 7A but positioned further within the weld nut to show a manner in which the pull plug deforms to conform to the part opening.

DETAILED DESCRIPTION

[0049] The reusable pull plug will now be described in detail with respect to the drawings, examples and information provided below. The structure of an exemplary pull plug according to the invention will first be described followed by an explanation of how the exemplary plug structure facilitates masking of an illustrative part opening. The preferred embodiments described herein are not intended to be exhaustive or to limit the invention to the precise form disclosed.

[0050] Referring first to FIGS. 1-5, those figures illustrate the main components of exemplary pull plug 10. Pull plug 10 includes a body 11, first and second ends 13, 15 and a body axis 17 defining an axial length 19 between the first and second ends 13, 15. The preferred plug body 11 is “segmented” (i.e., divided into portions) and includes a plug segment 21, a transition segment 23 and a tail segment 25. A flange 27 is provided at plug body first end 13. In the example shown, segments 21, 23 and 25 and flange 27 are coaxially aligned with axis 17 and are concentric to one another. Plug body 11 includes an outer surface 29 along the entire axial length 19 of the plug body 11, a first end surface 31 along the first end 13 and a second end surface 33 along the plug body second end 15.

[0051] Referring further to FIGS. 1-5 and 6A, flange 27 is formed between first end 13 and spaced apart flange edge surface 35 and has an axial length 32 between end 13 and edge surface 35. Flange 27 edge surface 35 may include an annular radius portion 36 at the junction of the flange 27 and the plug segment 21. The radius portion 36 facilitates removal of the plug 10 from the part opening by reducing shear force on flange 27 during removal of plug 10 from the part opening thereby extending the useful life of pull plug 10.

[0052] Flange 27 has a cross-sectional shape and area (collectively ref no. 37) at first end 13 in the section 38 transverse to axis 17 and bounded by outer surface 29. As shown in FIGS. 1-3 and 8-9, the preferred shape/area 37 is circular and preferred circular flange 27 has a diameter 40. Preferred flange 27 is coaxial with axis 17.

[0053] Plug body first end 13 surface 31 extends across flange 27 and defines a void volume 39 along first end 13. Preferably, void volume 39 is in communication with first end 13 and is coaxial with body axis 17 and concentric to preferred circular flange 27. The most highly preferred void volume 39 could be characterized as a “dimple” because such preferred void volume 39 has the appearance of a small indentation in the first end 13 and flange 27. The void volume 39, or dimple, facilitates radially-inward displacement and deformation of plug body segment 21 and flange 27 to fully mask the desired part surfaces and to facilitate removal of the plug 10 from the part thereby extending the service life of the plug 10.

[0054]FIGS. 1, 3, 6, 6A,7A-9 and 11-12 illustrate the most highly preferred form of void volume 39 which is in the form of a hemispherical dimple. As shown in FIGS. 3, 6A and 8, void volume 39 has a circular cross-sectional shape 41 in section 38 and the circular shape has a diameter 43. As well shown in FIG. 6A, void volume 39 has an axial length 42 between section 38 at first end 13 and surface 31. The axial length 42 of the most highly preferred hemispherical dimple 39 is a radius. The void volume axial length 42 is preferably between about 0.7-2.0 times the length of flange axial length 32.

[0055] Referring next to FIGS. 5-6 and 7-7A, plug segment 21 has an axial length 45 between plug segment first end 47 (at the junction with flange 27) and plug segment second end 49 (at the junction with transition segment 23). Plug segment 21 is preferably coaxial with body axis 17. Plug segment 21 has a first cross-sectional shape and area (collectively ref no. 51) at a section 53 transverse to axis 17 at the plug segment first end 47 and a cross-sectional shape and area (collectively ref no. 55) at a section 57 also transverse to the axis 17 taken at the plug segment second end 49. As shown in FIGS. 1-2 and 4, the preferred plug segment cross-sectional shapes/areas 51, 55 are circular. (In FIG. 4 the lead lines for reference numbers 51 and 55 appear to point to the same surface due solely to the fact that both spaced apart circular cross-sectional shapes 51, 55 taken in respective sections 53, 57 lie in the same two dimensional plane presented by the drawing.) Referring to FIGS. 1-2, 4-6 the cross-sectional area in sections 53, 57 bounded by outer surface 29 is preferably the same. Preferably, each plug segment 21 section taken transverse to axis 17 between ends 47, 49 has the same cross-sectional shape and area providing a plug segment 21 with the cylindrical configuration well shown in FIGS. 1-2, 5-6, 7-7A, 9-10 and 11. The cylindrical plug segment 21 has a diameter 59, 61 in each cross section 53, 57 and the preferred plug segment 21 bounds a volume as well shown particularly in FIGS. 1-2 and 9.

[0056] In the preferred embodiment illustrated, flange 27 protrudes radially outward from plug body 11 and the flange 27 is coaxial with body axis 17. The flange shape/area 37 defined by section 38 at first end 13 is greater than the shape/area 51, 55 of the plug segment 21 defined by sections 53, 57. Further, the void volume diameter 43 is about 0.20-0.60 the length of the flange diameter 40. Most preferably, the diameter 43 is 0.25 the length of the flange diameter 40.

[0057] Referring now to FIGS. 1-2, 5-6, 7, 7A and 9-10, transition segment 23 is coaxial with body axis 17 and has an axial length 63 between transition segment first end 65 (at the junction with plug segment 23) and transition segment second end 67 (at the junction with tail segment 25). Transition segment 23 has a first cross-sectional shape and area (collectively ref. no. 69) at section 57 at transition segment first end 65. Transition segment 23 has a further cross-sectional shape and area (collectively ref no. 71) at the section 73 transverse to axis 17 taken at the transition segment 23 second end 67. As shown in FIGS. 1-2 and 4, the preferred transition segment 23 cross-sectional shapes/areas 69, 71 are each circular. (In FIG. 4 the lead line for reference number 69 appears to point to the same surfaces as reference numbers 51, 55 due again to the two dimensional nature of the drawing.)

[0058] As is apparent from FIGS. 1-2, 4-6 and 10, the cross-sectional shape/area 69 bounded by outer surface 29 at section 57 is greater than the cross-sectional shape/area 71 bounded by outer surface 29 at section 73. As a result, the transition segment 23 has a frusto-conical configuration as is well shown in FIGS. 1-2, 5-6, 7, 7A and 10. The frusto-conical or otherwise tapered geometry of the transition segment 23 facilitates removal of the pull plug and reduces stresses between the plug 21 and tail 25 segments which would be present if there were no transition segment 23, that is if the plug 21 and tail 25 segments had a stepped configuration.

[0059] The tail segment 25 is well shown in FIGS. 1-2, 4, 5-6, 7, 7A, 9, 10 and 11.

[0060] Tail segment 25 is preferably coaxial with body axis 17 and is provided with an axial length 75 between tail segment first end 77 (at the junction with transition segment 23) and plug body second end 15. It is preferred, but not required, that the plug and tail segment have identical axial lengths 45, 75.

[0061] Tail segment 25 has a first cross-sectional shape and area (collectively ref no. 79) at section 73 located at the tail segment first end 77. Tail segment 25 has a further cross-sectional shape and area (collectively ref no. 81) at a section 83 transverse to axis 17 taken at the plug body second end 15. As shown in FIGS. 1-2 and 4, the preferred tail segment 23 cross-sectional shapes/areas 79, 81 are each circular. (As previously noted, FIG. 4 is a two-dimensional drawing and, consequently, the lead lines for reference numbers 79 and 81 appear to point to the same surface—which is not the case as surfaces 79 and 81 are in spaced apart sections 73 and 83 as shown in FIG. 5.) FIGS. 1-2, 4-6 and 10-11 show that the cross-sectional shape/area 79, 81 bounded by outer surface 29 at sections 73, 83 is the same. Further, each section along tail segment 25 transverse to axis 17 between ends 77 and 15 preferably has the same circular shape and area providing a tail segment 25 with the preferred cylindrical shape well shown, particularly in FIGS. 1-2, 4-6, 7, 7A, 9-10 and 11-12. As is also shown in these figures, the volume bounded by tail segment 25 is preferably less than the volume bounded by the plug segment 21.

[0062] The tail segment 25 is provided as an element which may be grasped and pulled so that the pull plug 10 can be pulled into the part opening and later removed from the part opening (following the coating or other operation) in the same direction in which the plug 10 was inserted into the part opening. The tail segment 25 typically has a volume less than the volume of the part opening which aids in inserting the plug into the opening. The tail segment 25 further facilitates insertion and removal of the plug 10 into a part opening because the low durometer materials used in the manufacture of plug body 11 will deform when compressed making it difficult to push the plug 10 through the part opening. Removal of the plug 10 in the same direction as inserted advantageously avoids damage to the coating applied over the plug 10 and the coated part. In fact, removal of the plug 10 in the same direction as insertion causes a clean break from the coating with a fine line at the edge of the coating with little or no coating build up and a very clean and appealing aesthetic appearance.

[0063] The plug body 11, including the flange 27 and plug 21, transition 23 and tail segments 25, is preferably a unitary member and is made of a molded elastomeric material. The material used in the manufacture of plug body 11 is selected so that the material has a durometer of between about 30-45 on a Shore A scale. Most preferably the material forming plug body 11 has a durometer of between about 35-45 on the Shore A scale. Materials suitable for use in manufacturing plug body 11 having a durometer within the required range include ethylene propylene (EPDM), butadiene acrylonitrile (NBR), styrene butadiene (SBR), fluorinated hydrocarbons (such as Viton™), polychloroprene (such as Neoprene™) and conductive silicone. Use of such materials to manufacture articles is well known to those of skill in the art.

[0064] The durometers required by the inventive plug body are outside the range of conventional pull plugs which typically have durometers of about 55+/−5 on the Shore A scale. Use of plug body materials with durometers lower than those of conventional plugs permits the outer surface 29 of the plug body 11 of the present invention to conform more closely to the part opening to be masked better shielding the part opening from contact by coatings or other materials. This advantageous result is not possible with conventional masking devices. Further, use of lower durometer materials, in combination with the void volume 39, permits the plug segment 23 and flange 27 to be displaced radially inward further facilitating conformation of the plug body 11 to the part opening. Close conformation of the plug body 11 to the part opening is of particular importance when seeking to completely mask irregular surfaces (i.e., threads, countersunk portions about the opening, and the like) around the part opening.

[0065] It has been observed that the flange can deform at angles of between about 90-180° to axis 17 permitting the flange to lie across and mask a countersunk opening formed around the part opening. Deformation of flange 27 at an angle of about 180° to axis 17 essentially allows flange 27 to fold fully out of the way of the part during removal of the plug 10 from the part opening facilitating removal of the plug 10 and minimizing stresses on the plug thereby extending the plug service life.

[0066] Variation is possible with respect to the geometry of the plug body 11. The plug segment 21 may have any configuration based on the specific part opening to be masked. The plug body 11 could include plug and transition segments 21, 23 which are other than cylindrical in configuration. For instance, the plug segment 21 need not have a cylindrical shape as shown in FIGS. 1-11 and could, instead, comprise a tapered shape in which the first end 47 in section 53 has a larger cross-sectional area than the second end 49 in section 57. The plug and transition segments 21, 23 need not have the same configuration. For example, one or both of the plug and tail segments 21, 25 could have a rectangular configuration. While the transition segment 23 must have a tapered configuration joining the plug and tail segments 21, 25, the transition segment 25 is not limited to the precise configuration presented in the drawings and need not have the preferred frusto-conical geometry illustrated in the drawings. Indeed, a separate transition segment 23 is not necessarily required. For example, a tail segment 25 with a tapered geometry could abut plug segment second end 49 and extend therefrom. The transition segment would, in effect, comprise an integral portion of the tail segment 25.

[0067] Void volume 39 may have a geometry other than the most highly preferred hemispherical, dimpled shape shown in the exemplary plug 10 although the void volume must permit radially-inward displacement of the plug segment 21 and flange 29 to permit the pull plug 10 to conform to the opening and to be removed from the opening. For example, the void volume 39 could have triangular, square, hexagonal or other suitable geometries. The hemispherical geometry shown in FIGS. 1, 3, 6, 6A, 9, 11 and 12 is most highly preferred because liquids and coatings are more easily discharged from the smooth surface 31 defining the void volume 39 minimizing the potential of contact between the interior portions of the part and coating in the void volume 39.

[0068] Referring next to FIGS. 7-12, the exemplary pull plug 10 will now be described in connection with masking of an illustrative part opening 85 in a weld nut 87. Weld nut 87 has a top surface 89 and side surfaces 91 formed in a hexagonal pattern. Weld nut 87 part opening 85 is defined by annular opening wall 93. Opening wall 93 includes threads 95 formed therein. As shown in FIGS. 7A and 12, a first thread 97 is formed in the opening annular inner edge surface 99. Edge 99 is provided with a chamfer, or bevel, which is typically at an angle of about 45° to the wall 93 thereby exposing the first thread 97 along top surface 89. It is difficult to fully mask edge 99 about opening 85 because it is difficult to conform a masking device to the chamfered edge 99 profile and uniquely irregular surface provided by the first thread 97.

[0069] Weld nut 87 is attached by a weld 109 to a surface of which plate 101 is exemplary. Opening 93 is in coaxial alignment with opening 103 formed in plate 101. A threaded fastener, such as a bolt (not shown) may be coupled to the plate 101 by threaded engagement with threads 95 of weld nut 87.

[0070] Plug 10 is provided to mask part opening 85 so that the wall 93, threads 95, first thread 97 and chamfered edge 99 are covered and shielded from contact by coating material applied to plate 101 and weld nut 87. Alternatively, plug 10 could be used to cover opening 85 to prevent weld flux or other contaminants being deposited along wall 93, threads 95, first thread 97 or chamfered edge 99.

[0071] It should be emphasized that plug 10 is not limited to use in applications such as those illustrated in FIGS. 7-12. Plug 10 is useful to mask any part opening including part openings which are threaded, non-threaded and those part openings which have irregular surfaces. By way of further example, plug 10 may be used with parts having interior surfaces in communication with the part opening. In such applications, plug 10 masks the part opening (such as opening 85) to prevent coating or other material from flowing along the opening (or any passageway formed by threads along the wall defining the part opening) and into contact with the interior surfaces of the part. Plug 10 is useful to mask chamfered, stepped, spot faced and threaded surfaces surrounding many different types of part openings.

[0072] Referring then to FIGS. 7-9, tail segment 25 is first inserted partially into opening 85 in the direction of arrow 105. Plug 10 is sized so that the plug segment 21 is oversized relative to the opening 85 thereby providing a frictional fit between plug outer surface 29 and threads 95 or wall 93 firmly holding plug 10 in place in opening 85. In the examples shown, plug 10 is to be used to mask a part opening having an annular wall 93 and threads 95 defining the opening 85. Plug 10 is selected such that the plug section 21 diameter (i.e., diameters 59 and/or 61) is equal to or greater than the diameter 107 of the annular opening 85.

[0073] Referring next to FIGS. 10-12, the plug tail 25 is grasped and pulled further in the direction of arrow 105 until the plug segment 21 is firmly seated against threads 95 or against threads 95 and wall 93. As shown in FIG. 12, void volume 39 permits substantially uniform partial displacement of plug segment 21 and flange 27 in a radially-inward direction to permit plug 10 to be seated along wall 93 and threads 95. Also as shown in FIG. 12, the low durometer material forming plug body 11 permits the body 11 (particularly outer surface 29) to conform to the profile of threaded inner wall 93 sealing the helical passageway formed by threads 95 thereby preventing coating material from moving along the threads 95.

[0074] Masking of the part opening 85 is completed by the co-action of the flange 27 and void volume 39. As shown best in FIGS. 10A and 12, flange 27 edge surface 35 contacts first thread 97 and chamfered edge 99 along top surface 89. The flange 27 then deforms at an angle of between about 90-180° to axis 17 depending on the extent of movement of pull plug 10 through opening 85 in the direction of arrow 105. For example and as shown in FIG. 10, if it is desired to mask weld nut top surface 89 to the full extent of the flange shape 37 and area (i.e., the flange 27 footprint), then the pull plug will be pulled through the opening 85 until flange edge surface 35 meets weld nut top surface 89. In this arrangement shown in FIG. 10A, flange 27 is not deformed and is at an angle of 90° to axis 17.

[0075] By way of further example and as shown in FIG. 12, if it is desired to mask only the first thread 97, chamfered edge 99 and opening 85 (and not weld nut top surface 89) then the plug 10 is pulled further through opening 85 further in the direction of arrow 105 to the position shown in FIG. 12. Flange 27 will deform at an angle of between about 100-180° to axis 17 with edge surface 35 conforming to first thread 97 and chamfered edge 99 masking those surfaces. The deformation is facilitated by void volume 39 which, as described and shown in FIG. 12, permits displacement of the plug segment in a radial-inward direction. In FIG. 12 the flange is shown deformed at an angle of roughly 135° to axis 17. Coating or other material can reach those portions of weld nut top surface 89 which are not in contact with flange edge surface 35. The deformation of flange 27 as shown in FIG. 12 also permits the flange 27 to conform to and mask countersunk portions (not shown) around a part opening.

[0076] Following completion of the coating or other operation the plug 10 is removed by grasping tail segment 25 and by pulling plug 10 through opening 93 again in the direction of arrow 105. The flange 27 deforms at an angle of about 180° to axis 17 to facilitate full passage of the plug 10 through the opening 85. Movement of the plug 10 fully through opening 85 is further facilitated by the optional radius portion 36 which decreases shear against the flange 27 as the plug 10 is pulled through opening 85.

[0077] An important advantage of the inventive plug 10 versus conventional washer plugs is the capability of the pull plug 10 to be removed through part opening 85 in the direction of arrow 105. Removal of the plug 10 in the same direction as insertion of the plug 10 results in a clean break between the plug 10 and the applied coating improving the appearance of the coated part and reducing defects in the coating.

EXAMPLES AND DATA Example 1

[0078] An important advantage of the inventive plug 10 is that a single pull plug 10 can be used to mask a wide range of part openings each having different opening sizes. As a result, an operator need not maintain as great an inventory of plugs for the operator's coating or other operation. Since thousands of plugs in different sizes may be needed to operate a large scale coating operation, this can result in significant savings in inventory and material for the operator. This advantageous result is possible because of the combination of (1) the void volume 39; and (2) the novel plug body 11 made of the highly deformable material having a low durometer value of 35-45 on the Shore A scale. The combination of these elements permits one plug 10 to deform to fit many smaller part openings (such as opening 85).

[0079] A comparison of prior art pull plugs and pull plugs of the invention was conducted to determine the range of part openings which could be fully masked with a single size plug. The conventional and inventive plugs each had plug, transition and tail segments. The diameter of the plug segments was 0.217 inches. The conventional plug was not provided with a dimple or flange and was made of silicone rubber having a durometer of 55+/−5.

[0080] The conventional and inventive plugs were inserted in a range of English course threaded template openings to determine their overall fit and application range. The table that follows shows the versatility of the inventive plug over the conventional plug. TABLE 1 Comparison of Range of Part Openings Capable of Being Masked by One Plug Size Plug Durometer Void Segment Size Range of Part Pull Plug (Shore A Volume Diameter Openings Masked Type Scale) Diameter (Inches) (Inches) Conventional 55 +/− 5 None- 0.217 ¼-20 threaded hole No void (approximately .205 to volume .215″ diameter holes) Invention 40 +/− 5 .0827 0.217 ¼-20, ¼-28 and M6 × 1.00 holes (approximately .190-.215″ diameter holes)

[0081] The data shows that the plug of the invention is capable of fully masking a broader range of part openings than the conventional plug.

Example 2

[0082] A further important advantage of the inventive plug 10 is that a single pull plug 10 can be repeatedly reused during the course of many coating cycles. The ability to reuse the plug permits an operator to maintain a smaller inventory of plugs for the operator's coating or other operation. Again, this can result in significant savings in inventory and material for the operator.

[0083] Control and inventive pull plugs having the geometry of the plugs shown in FIGS. 1-12 were manufactured. The plugs had identical flanges 27 and plug 21, transition 23 and tail 25 segments. Both plugs were made of virgin silicone. The plugs differed only in that the control plug lacked a void volume 39 and had a durometer of 55+/−5 on the Shore A scale while the inventive plug included a hemispherical void volume 39 as shown in FIGS. 1-12 and had a durometer of 40+/−5 on the Shore A scale.

[0084] The pull plugs were inserted into a ¼-20 threaded opening in a template and were pulled completely through the template in successive cycles until failure of the plug flange was observed. The control plug without the void volume tore along the flange after 3-5 cycles. The inventive plug remained intact through an average of 50 cycles. The data show that the void volume and lower durometer material contribute to an extended service life.

[0085] It is believed that the invention has been described in such detail as to enable those skilled in the art to understand the same and it will be appreciated that variations may be made without departing from the spirit and scope of the invention. 

1. In a reusable pull plug for masking a part opening defined by at least one part wall, the plug having a plug body, first and second ends, a body axis, an axial length between the first and second ends, a plug segment adjacent the first end and a tail segment between the plug segment and plug second end, the improvement wherein: the plug body is elastomeric and has a durometer of between about 30-45 on the Shore A scale; the plug body includes a flange along the first end adjacent a plug segment first end, the flange and plug segment first end each have a cross-sectional shape and area transverse to the body axis and the flange cross-sectional area is greater than the plug segment cross-sectional area; and the plug body includes a first end surface defining a void volume along the first end, said void volume facilitating radially-inward deformation of the flange and plug body segment to facilitate conformation of the plug to the at least one part wall defining the part opening.
 2. The pull plug of claim 1 wherein the plug body further includes a tapered transition segment between the plug segment and the tail segment.
 3. The pull plug of claim 2 wherein the plug segment further includes a second end adjacent the transition segment having a cross-sectional shape and area transverse to the body axis, an axial length between the plug segment first and second ends and the plug segment first end cross-sectional area is substantially the same as the plug segment second end cross-sectional area.
 4. The pull plug of claim 3 wherein each cross-section transverse to the body axis between the plug segment first and second ends has substantially the same shape and area.
 5. The pull plug of claim 4 wherein each cross-sectional shape is circular.
 6. The pull plug of claim 3 wherein the transition segment includes a first end adjacent the plug segment second end having a cross-sectional shape and area transverse to the body axis, a second end having a cross-sectional shape and area transverse to the body axis, an axial length between the transition segment first and second ends and the transition segment first end cross-sectional area is greater than the transition segment second end cross-sectional area.
 7. The pull plug of claim 6 wherein each transition segment first and second end cross-sectional shape is circular.
 8. The pull plug of claim 6 wherein the tail segment includes a first end adjacent the transition segment second end having a cross-sectional shape and area transverse to the body axis, a second end at the body second end having a cross-sectional shape and area transverse to the body axis, an axial length between the tail segment first and second ends and the tail segment first end cross-sectional area is substantially the same as the tail segment second end cross-sectional area.
 9. The pull plug of claim 8 wherein each cross-section transverse to the body axis between the tail segment first and second ends has substantially the same shape and area.
 10. The pull plug of claim 9 wherein each cross-sectional shape is circular.
 11. The pull plug of claim 8 wherein the plug segment first and second end cross-sectional areas are greater than the tail segment first and second end cross-sectional areas.
 12. The pull plug of claim 8 wherein the plug segment and tail segment axial lengths are substantially the same.
 13. The pull plug of claim 1 wherein the body is a unitary element.
 14. The pull plug of claim 13 wherein the plug body is made of a material selected from the group consisting of ethylene propylene, butadiene acrylonitrile, styrene butadiene, fluorinated hydrocarbons, polychloroprene and conductive silicone.
 15. The pull plug of claim 14 wherein the plug body has a durometer of between about 35-45 on the Shore A scale.
 16. The pull plug of claim 1 wherein the flange has an axial length between the plug first end and a spaced apart flange edge surface, the void volume has an axial length between the plug first end and the plug first end surface and the void volume axial length is between about 0.7 to 2.0 times the flange axial length.
 17. The pull plug of claim 1 wherein the void volume is a dimple.
 18. The pull plug of claim 17 wherein the dimple has a hemispherical geometry
 19. The pull plug of claim 18 wherein the hemispherical dimple has a circular cross-sectional shape and area transverse to the body axis at the plug first end and a diameter.
 20. The pull plug of claim 19 wherein the flange cross-sectional shape is circular and the flange has a diameter and the dimple diameter is between about 0.20-0.60 of the flange diameter.
 21. The pull plug of claim 1 wherein the flange is deformable at an angle of between about 90-180° to the body axis.
 22. A reusable pull plug for masking a part opening defined by at least one part wall comprising: a unitary plug body having an outer surface, a body axis, first and second ends and an axial length between the first and second ends, said body being made of an elastomeric material having a durometer between 30-45 on the Shore A scale; a cylindrically-shaped flange formed in the body first end coaxially aligned with the body axis, said flange having an axial length between the body first end and a spaced apart flange edge surface and a flange diameter; a cylindrically-shaped plug segment formed in the body coaxially aligned with the body axis, said plug segment having a first end adjacent the flange, a second end, an axial length between the plug segment first and second ends; a tapered transition segment formed in the body coaxially aligned with the body axis, said transition segment having a first end adjacent the plug segment second end, a second end and an axial length between the transition segment first and second ends; a cylindrically-shaped tail segment formed in the body coaxially aligned with the body axis, said tail segment having a first end adjacent the transition segment second end, a second end at the body second end and an axial length between the tail segment first and second ends; and a first end surface along the body first end forming a dimple coaxially aligned with the body axis, said dimple having a diameter between about 0.20-0.60 of the flange diameter; whereby the pull plug flange and plug segment are deformable to facilitate conformation of the plug outer surface to the at least one part wall defining the part opening.
 23. The pull plug of claim 21 wherein the dimple has an axial length between the plug first end and the first end surface and the dimple axial length is between about 0.7-2.0 times the flange axial length.
 24. The pull plug of claim 23 wherein the plug segment has a volume, the tail segment has a volume which is less than the plug segment volume and the plug segment and tail segment axial lengths are substantially the same.
 25. The pull plug of claim 24 wherein the plug body has a durometer of between about 35-45 on the Shore A scale.
 26. The pull plug of claim 25 wherein the plug body is made of a material selected from the group consisting of ethylene propylene, butadiene acrylonitrile, styrene butadiene, fluorinated hydrocarbons, polychloroprene and conductive silicone.
 27. The pull plug of claim 26 wherein the flange is deformable at an angle of between about 90-180° to the body axis. 